US8974831B2 - Process for preparing carrier particles for dry powders for inhalation - Google Patents

Process for preparing carrier particles for dry powders for inhalation Download PDF

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US8974831B2
US8974831B2 US13/078,057 US201113078057A US8974831B2 US 8974831 B2 US8974831 B2 US 8974831B2 US 201113078057 A US201113078057 A US 201113078057A US 8974831 B2 US8974831 B2 US 8974831B2
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particles
lactose
magnesium stearate
carrier
pharmaceutical composition
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US20110262547A1 (en
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Rossella Musa
Daniela Cocconi
Alain Chamayou
Laurence Galet
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Chiesi Farmaceutici SpA
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Chiesi Farmaceutici SpA
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • A61K9/1682—Processes
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K31/00—Medicinal preparations containing organic active ingredients
    • A61K31/16—Amides, e.g. hydroxamic acids
    • A61K31/165—Amides, e.g. hydroxamic acids having aromatic rings, e.g. colchicine, atenolol, progabide
    • A61K31/167—Amides, e.g. hydroxamic acids having aromatic rings, e.g. colchicine, atenolol, progabide having the nitrogen of a carboxamide group directly attached to the aromatic ring, e.g. lidocaine, paracetamol
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K31/00—Medicinal preparations containing organic active ingredients
    • A61K31/33—Heterocyclic compounds
    • A61K31/395—Heterocyclic compounds having nitrogen as a ring hetero atom, e.g. guanethidine or rifamycins
    • A61K31/40—Heterocyclic compounds having nitrogen as a ring hetero atom, e.g. guanethidine or rifamycins having five-membered rings with one nitrogen as the only ring hetero atom, e.g. sulpiride, succinimide, tolmetin, buflomedil
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K31/00—Medicinal preparations containing organic active ingredients
    • A61K31/56—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids
    • A61K31/57—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids substituted in position 17 beta by a chain of two carbon atoms, e.g. pregnane or progesterone
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K31/00—Medicinal preparations containing organic active ingredients
    • A61K31/56—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids
    • A61K31/57—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids substituted in position 17 beta by a chain of two carbon atoms, e.g. pregnane or progesterone
    • A61K31/573—Compounds containing cyclopenta[a]hydrophenanthrene ring systems; Derivatives thereof, e.g. steroids substituted in position 17 beta by a chain of two carbon atoms, e.g. pregnane or progesterone substituted in position 21, e.g. cortisone, dexamethasone, prednisone or aldosterone
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/0012—Galenical forms characterised by the site of application
    • A61K9/007—Pulmonary tract; Aromatherapy
    • A61K9/0073—Sprays or powders for inhalation; Aerolised or nebulised preparations generated by other means than thermal energy
    • A61K9/0075—Sprays or powders for inhalation; Aerolised or nebulised preparations generated by other means than thermal energy for inhalation via a dry powder inhaler [DPI], e.g. comprising micronized drug mixed with lactose carrier particles
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/141—Intimate drug-carrier mixtures characterised by the carrier, e.g. ordered mixtures, adsorbates, solid solutions, eutectica, co-dried, co-solubilised, co-kneaded, co-milled, co-ground products, co-precipitates, co-evaporates, co-extrudates, co-melts; Drug nanoparticles with adsorbed surface modifiers
    • A61K9/145—Intimate drug-carrier mixtures characterised by the carrier, e.g. ordered mixtures, adsorbates, solid solutions, eutectica, co-dried, co-solubilised, co-kneaded, co-milled, co-ground products, co-precipitates, co-evaporates, co-extrudates, co-melts; Drug nanoparticles with adsorbed surface modifiers with organic compounds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/48—Preparations in capsules, e.g. of gelatin, of chocolate
    • A61K9/50—Microcapsules having a gas, liquid or semi-solid filling; Solid microparticles or pellets surrounded by a distinct coating layer, e.g. coated microspheres, coated drug crystals
    • A61K9/5005—Wall or coating material
    • A61K9/5015—Organic compounds, e.g. fats, sugars
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P11/00—Drugs for disorders of the respiratory system
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P11/00—Drugs for disorders of the respiratory system
    • A61P11/02—Nasal agents, e.g. decongestants
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P11/00—Drugs for disorders of the respiratory system
    • A61P11/06—Antiasthmatics
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61P—SPECIFIC THERAPEUTIC ACTIVITY OF CHEMICAL COMPOUNDS OR MEDICINAL PREPARATIONS
    • A61P37/00—Drugs for immunological or allergic disorders
    • A61P37/08—Antiallergic agents

Definitions

  • the present invention relates to processes for preparing carrier particles for use in dry powder formulations for inhalation.
  • the present invention also relates to carrier particles produced by such a process and dry powder formulations prepared with such carrier particles.
  • the present invention further relates to methods for the treatment and/or prevention of certain diseases and conditions by administering such a dry powder formulation.
  • DPI Dry powder inhalation
  • Dry powder forms are typically formulated by mixing the drug in micronized form with coarse carrier particles, giving rise to an ordered mixture where the micronized active particles adhere to the surface of the carrier particles whilst in the inhaler device.
  • the carrier makes the micronized powder less cohesive and improves its flowability, making it easier to handle the powder during the manufacturing process (pouring, filling, etc.).
  • the drug particles separate from the surface of carrier particles and penetrate into the lower lungs, while the larger carrier particles are mostly deposited in the oropharyngeal cavity.
  • the re-dispersion of drug particles from the carrier surface is regarded as the most critical factor which governs the availability of the medicament to the lungs. This will depend on the mechanical stability of the powder mix and the way this is influenced by the adhesion characteristics between the drug and the carrier and the external forces required to break up the non covalent bonds formed between adhering particles. Too strong bonds between adhering particles may indeed prevent the separation of the micronized drug particles from the surface of carrier particles.
  • improved carrier particles may be obtained by a process which comprises subjecting particles made of lactose to dry coating with magnesium stearate to provide a surface coating of the lactose particles, wherein said dry coating is carried out in a high shear mixer granulator based on friction behavior.
  • the present invention provides a process for the preparation of a carrier for powder pharmaceutical compositions for inhalation, the process comprising subjecting particles made of lactose having a mass diameter in the range 30 to 1000 microns to dry coating with 0.1 to 1.3% magnesium stearate by weight of the carrier, to provide a surface coating of the lactose particles with said magnesium stearate to an extent such that the coated particles have more than 60% of surface coating, wherein the dry coating step is carried out in a high shear mixer granulator based on friction behavior, at a rotation speed equal to or higher than 500 r.p.m, preferably equal to or higher than 1000 r.p.m., but equal to or lower than 2500 r.p.m, preferably lower than 2000 r.p.m.
  • said high shear mixer granulator is the CYCLOMIXTM apparatus.
  • the present invention provides carrier particles for dry powder formulations for inhalation, said carrier particles comprising particles of lactose having a mass diameter in the range 30 to 1000 microns coated with 0.1 to 1.3% magnesium stearate by weight of the carrier, to an extent such that the coated particles have more than 60% of surface coating, said carrier particles being obtainable by a process which comprises the step of dry coating in a high shear mixer granulator based on friction behavior between the aforementioned lactose particles and magnesium stearate at a rotation speed equal to or higher than 500 r.p.m, preferably equal to or higher than 1000 r.p.m, but equal to or lower than 2500 r.p.m, preferably lower than 2000 r.p.m.
  • the present invention provides carrier particles for dry powder formulations for inhalation, said carrier particles comprising particles of lactose having a mass diameter in the range 30 to 1000 microns coated with 0.1 to 1.3% magnesium stearate by weight of the carrier to an extent such that the coated particles have more than 60% of surface coating.
  • the present invention provides a pharmaceutical composition in the form of a dry powder for inhalation comprising the carrier particles of the present invention and one or more active ingredients.
  • the present invention provides a dry powder inhaler filled with the aforementioned dry powder pharmaceutical composition.
  • the present invention provides a process for preparing the aforementioned pharmaceutical composition comprising a step of mixing the carrier particles of the present invention with one or more active ingredient.
  • the present invention is also directed to a package comprising a dry powder pharmaceutical formulation according to the present invention and a dry powder inhaler.
  • the present invention provides methods for the treatment and/or prevention of certain diseases and conditions by administering the aforementioned dry powder pharmaceutical composition.
  • FIG. 1 is a scheme of the film forming process around a single carrier particle
  • FIG. 2 shows SEM pictures at different magnifications of: lactose particles +0.5% magnesium stearate at 1500 r.p.m. for 5 minutes (top left, scale 200 microns; bottom left, scale 100 microns); lactose particles +0.5% magnesium stearate at 1500 r.p.m. for 10 minutes (top middle, scale 500 microns; bottom middle, scale 100 microns); lactose particles +0.5% magnesium stearate at 1500 r.p.m. for 15 minutes (top right, scale 500 microns; bottom right, scale 100 microns); and
  • FIG. 3 is a graph which shows water adsorption at increasing percentage of relative humidity.
  • active drug active drug
  • active ingredient active ingredient
  • active substance active compound
  • active compound active compound
  • therapeutic agent therapeutic agent
  • high shear mixer granulator based on friction behavior refers to an apparatus fitted with paddle shape mixing elements wherein the particles are accelerated by the paddles and intensively mixed by the friction against the vessel wall.
  • dry coating refers to a mechanical process wherein a first material (i.e. magnesium stearate) form a physical interaction (coating) with a second material (i.e. carrier) in dry conditions, e.g. without solvents, binders or water.
  • first material i.e. magnesium stearate
  • second material i.e. carrier
  • surface coating refers to the covering of the surface of the carrier particles by forming a film of magnesium stearate around said particles as reported in the diagram shown in FIG. 1 .
  • the thickness of the film has been estimated by X-ray photoelectron spectroscopy (XPS) to be approximately of less than 10 nm.
  • the percentage of surface coating indicates the extent by which magnesium stearate coats the surface of all the carrier particles.
  • hygroscopic refers to an active compound that never completely dries in contact with air having a moisture content of >0% relative humidity, but always contains a certain amount of absorptively bound water (see, H. Sucker, P. Fuchs and P. Suiter: Pharmaceutical Technology , Georg Thieme Verlag, Stuttgart, N.Y., 2nd edition 1991, page 85, which is incorporated herein by reference).
  • hydrophilic refers to an active compound that can easily be wetted by water.
  • formoterol is a typical hydrophilic active ingredient.
  • the particle size of the particles is quantified by measuring a characteristic equivalent sphere diameter, known as volume diameter, by laser diffraction.
  • the particle size can also be quantified by measuring the mass diameter by means of suitable instruments and techniques known to the skilled person, such as sieving.
  • the volume diameter (VD) is related to the mass diameter (MD) by the density of the particles (assuming the size being independent from the density of the particles).
  • the particle size interval is expressed in terms of mass diameter. Otherwise, the particle size distribution is expressed in terms of: i) the volume median diameter (VMD) which corresponds to the diameter of 50 percent by weight or volume respectively, of the particles, e.g. d(v0.5); and ii) the volume diameter (VD) in microns of 10% and 90% of the particles, respectively, e.g. d(v0.1) and d(v0.9).
  • VMD volume median diameter
  • good flow properties refers to a formulation that is easy handled during the manufacturing process and is capable of ensuring an accurate and reproducible delivery of the therapeutically effective dose.
  • Flow characteristics can be evaluated by measuring the Can's index; a Carr's index of less than 25 is usually taken to indicate good flow characteristics.
  • good homogeneity refers to a formulation wherein, upon mixing, the content uniformity of the active ingredient, expressed as relative standard deviation (RSD), is less than 5%, preferably equal to or less than 2.5%.
  • RSS relative standard deviation
  • the expression “physically stable in the device before use” refers to a formulation wherein the active particles do not substantially segregate and/or detach from the surface of the carrier particles both during manufacturing of the dry powder and in the delivery device before use.
  • the tendency to segregate can be evaluated according to Staniforth et al., J. Pharm. Pharmacol. , vol. 34, pp. 700-706 (1982), which is incorporated herein by reference in its entirety, and it is considered acceptable if the distribution of the active ingredient in the powder formulation after the test, expressed as relative standard deviation (RSD), does not change significantly with respect to that of the formulation before the test.
  • RSD relative standard deviation
  • respirable fraction refers to an index of the percentage of active ingredient particles which would reach the deep lungs in a patient.
  • the respirable fraction also termed fine particle fraction (FPF)
  • FPF fine particle fraction
  • MLSI Multi Stage Liquid Impinger
  • a respirable fraction higher than 30% is an index of good inhalatory performances.
  • therapeutic amount means the amount of active ingredient that when delivered to the lungs via a dry powder formulation as described herein provides the desired biological effect.
  • single dose it is meant the quantity of active ingredient administered at one time by inhalation upon actuation of the inhaler.
  • actuation it is meant the release of active ingredient from the device by a single activation (e.g. mechanical or breath).
  • the present invention is directed to processes for the preparation of a carrier for powder pharmaceutical compositions for inhalation, the process comprising subjecting particles made of lactose to dry coating with magnesium stearate to provide a surface coating of the lactose particles, wherein said dry coating is carried out in a high shear mixer granulator based on friction behavior.
  • Magnesium stearate is an additive with lubricant properties that is mainly used for increasing the respirable fraction of the active ingredient.
  • Ant type of magnesium stearate of pharmaceutical grade commercially available may be used, despite of its origin.
  • the amount of magnesium stearate should be 0.1 to 1.3% by weight based on the weight of the carrier in such a way that the relevant formulation retains its homogeneity during conditions that are comparable to those that might occur during commercial processing.
  • the amount of magnesium stearate may be 0.15 to 1.0% by weight (w/w).
  • magnesium stearate will depend on both the dry powder inhaler and the active ingredient employed in the powder formulation.
  • the skilled person will have an understanding of the physical and chemical properties of the active ingredient and the type of inhaler, for example single dose or multidose, and be able to select an appropriate amount.
  • the amount of magnesium stearate may 0.15 to 0.5% w/w, more preferably 0.2 to 0.4% w/w, or 0.1 to 0.3% w/w, based on the weight of the carrier. In other embodiments, it may be 0.3 to 0.5% w/w or 0.4 to 1.0% w/w, more preferably 0.5 to 0.8% by weight based on the weight of the carrier. In further embodiments, it may be 0.65 to 1.25% w/w, preferably 0.7 to 1.1% w/w, based on the weight of the carrier. In a particular embodiment, the amount of magnesium stearate is 0.1% w/w, based on the weight of the carrier.
  • the amount of magnesium stearate will depend on the particle size and hence on the surface area of the carrier particles.
  • the amount of magnesium stearate will be preferably 0.65 to 1.25% w/w, while with carrier particles having a smaller surface area such those having a bigger particle size, e.g. 90 to 150 microns, the amount will be preferably 0.1 to 0.3% w/w.
  • the lactose particles may be any type of crystalline lactose or mixture thereof.
  • the lactose particles are made of alpha-lactose or beta-lactose or solvates thereof
  • the carrier particles are particles of alpha-lactose monohydrate.
  • All of the lactose particles have a mass diameter in the range of 30 to 1000 microns. Particles having a mass diameter of 50 to 500 microns may be advantageously used. In a preferred embodiment, the mass diameter is 60 to 200 microns. In particular embodiments, particles having a mass diameter of 60 to 90 microns or 90 to 150 microns may be used. In other embodiments, the mass diameter is 150 to 400 microns or 210 to 355 microns.
  • the size of the carrier particles is an important factor in the efficiency of the inhaler.
  • the desired particle size may be obtained by sieving.
  • the particle size distribution fulfils the following parameters: d(v0.1) of 85 to 100 microns, d(v0.5) of 125 to 135 microns, and d(v0.9) of 180 to 190 microns.
  • the lactose particles are subjected to dry-coating with magnesium stearate particles until the extent of surface coating is higher than 60%, advantageously equal to or higher than 70%, more advantageously of at least 80%, preferably equal to or higher than 85%, more preferably equal to or higher than 90%, even more preferably equal to or higher than 95%. Under particular conditions, it might be possible to achieve a surface coating of 100%. Although it may be possible to achieve a surface coating of 100%, a lower percentage of surface area coating may be a more practical upper limit, such as 99.9%, 99%, 98%, 97%, or 96%.
  • f MgSt and f lactore are the surface area fractions of magnesium stearate and of lactose
  • ⁇ MgSt is the water contact angle of magnesium stearate
  • ⁇ lactose is the water contact angle of lactose
  • ⁇ mixture are the experimental contact angle values.
  • the measure of the contact angle between a liquid and a solid surface is commonly used in the art for determining the wettability of solids. This approach is based on the capability of a liquid to spread spontaneously over the surface of a solid to reach a thermodynamic equilibrium.
  • the contact angle may be determined with methods that are essentially based on goniometric measurements. These imply the direct observation of the angle formed between the solid substrate and the liquid under testing. It is therefore quite simple to carry out, being the only limitation related to possible bias stemming from intra-operator variability. It should be, however, underlined that this drawback can be overcome by adopting a fully automated procedure, such as a computer assisted image analysis.
  • a particularly useful approach is the sessile or static drop method as referenced on page 332 of Colombo et al. (ibidem), that is carried out by depositing a liquid drop onto the surface of the powder in the form of a disc obtained by compaction (compressed powder disc method).
  • the compressed disc is prepared by adding the sample into the die of a press and a compression force of 5 kN is applied for 3 minutes. Then the compressed disc is placed on a plate of a surface wettability tester and a water drop of about 10 ⁇ l is formed on the surface of the disc.
  • a suitable surface wettability tester is, for example, that available from Lorentzen & Wettre GmbH.
  • the pictures are taken with a videocamera and the water contact angles values are given by a computer assisting in the analysis of the image.
  • the values are calculated as a mean of three different measurements taken at room temperature.
  • the precision is usually of about ⁇ 5°.
  • the extent to which the magnesium stearate coats the surface of the lactose particles may also be determined by X-ray photoelectron spectroscopy (XPS), a well known tool for determining the extent as well as the uniformity of distribution of certain elements on the surface of other substances.
  • XPS X-ray photoelectron spectroscopy
  • photons of a specific energy are used to excite the electronic states of atoms below the surface of the sample.
  • Electrons ejected from the surface are energy filtered via a hemispherical analyser (HSA) before the intensity for a defined energy is recorded by a detector. Since core level electrons in solid-state atoms are quantized, the resulting energy spectra exhibit resonance peaks characteristic of the electronic structure for atoms at the sample surface.
  • HSA hemispherical analyser
  • XPS measurements are taken on an Axis-Ultra instrument available from Kratos Analytical (Manchester, UK) using monochromated Al K ⁇ radiation (1486.6 eV) operated at 15 mA emission current and 10 kV anode potential (150 W).
  • a low energy electron flood gun is used to compensate for insulator charging.
  • Survey scans, from which quantification of the detected elements are obtained, are acquired with analyser pass energy of 160 eV and a 1 eV step size.
  • High-resolution scans of the C 1 s, O 1 s, Mg 2 s, N 1 s and Cl 2 p regions are acquired with pass energy of 40 eV and a 0.1 eV step size.
  • the area examined is approximately 700 ⁇ m ⁇ 300 ⁇ m for the survey scans and a 110 ⁇ m diameter spot for the high-resolution scans.
  • Mg sample is the amount of Mg in the analyzed mixture
  • Mg ref is the amount of mg in the reference sample of commercially available MgSt.
  • XPS measurements may be taken with commercially available instruments such as Axis-Ultra instrument from Kratos Analytical (Manchester UK), typically using monochromated Al K ⁇ radiation according to known procedures.
  • SEM scanning electron microscopy
  • Such microscopy may be equipped with an EDX analyzer (an Electron Dispersive X-ray analyzer), that can produce an image selective to certain types of atoms, for example magnesium atoms. In this manner it is possible to obtain a clear data set on the distribution of magnesium stearate on the surface of carrier particles.
  • EDX analyzer an Electron Dispersive X-ray analyzer
  • SEM may alternatively be combined with IR or Raman spectroscopy for determining the extent of coating, according to known procedures.
  • the apparatus in which the process of the invention is carried out should be a high shear mixer granulator based on friction, operating at a rotation speed equal to or higher than 500 r.p.m., but equal to or lower than 2500 r.p.m, preferably between 500 and 2000 r.p.m., more preferably 1000 to 1500 r.p.m.
  • the carrier particles have a mass diameter equal to or higher than 90 microns, at a rotation speed of 2000 r.p.m., the particles of lactose begin to break, and hence a significant reduction of the particle size is observed.
  • a typical high shear mixer granulator which can be employed for carrying out the process of the invention is the CYCLOMIXTM apparatus (Hosokawa Micron Group Ltd).
  • Said apparatus comprises a stationary conical vessel fitted with paddle-shaped mixing elements, which rotate close to the inner vessel wall.
  • the rotation of the paddles and the conical shape of the vessel force the powder from the bottom to the upper zone of the vessel.
  • the powder flows downwards into the centre of the vessel. This flow pattern results in fast macromixing.
  • the particles of the powder are accelerated by the paddles and intensively mixed by friction with vessel. Such effects are sufficient to soften, break, distort, flatten, and wrap the particles of magnesium stearate around the carrier particles to form a coating.
  • the product temperature remained constant during all the experiments. However, the temperature may be controlled in an accurate and reliable way.
  • the particle size of the lactose particles remains substantially the same and a high extent of coating is achieved.
  • the rotation speed would be preferably maintained equal to or lower than 1500 r.p.m., i.e. between 1000 and 1500 r.p.m., whereas at higher rotating speeds it would be possible to produce in situ a small percentage of fine carrier particles as reported for example in WO 00/53158.
  • a fraction of not more than 10% of fine particles can be produced with a MMD lower than 20 microns, preferably lower than 10 microns.
  • the time of processing depends of the type of carrier particles and on the size of the batch and shall be adjusted by the skilled person.
  • the time of processing is 1 to 30 minutes, preferably 2 to 20 minutes, more preferably 5 to 15 minutes.
  • the time of processing is about 10 minutes.
  • the time of processing would also affect the extent of coating and it would be adjusted by the skilled person depending on the amount of magnesium stearate employed and the extent of coating desired.
  • Carriers obtainable by the process of the present invention exhibit good flow properties, as they have a Carr's index well below the value of 25, which is usually taken as a discriminating value for free flowing powders.
  • dv is the poured density
  • ds is the tapped density
  • Powder mixtures (about 70 g) were poured into a glass graduated cylinder and the unsettled apparent volume V 0 was read; the apparent density before settling (poured density, dv) was calculated dividing the weight of the sample by the volume V 0 .
  • the apparent volume after settling (V 1250 ) was read and the apparent density after settling (tapped density, ds) was calculated.
  • compositions comprising the carrier of the present invention also show good aerosol performance in terms of respirable fraction and significantly higher aerosol performances than formulations comprising a carrier prepared according to U.S. Pat. No. 6,528,096.
  • the percentage of respirable magnesium stearate particles delivered by the carrier of the invention is significant lower that the percentage delivered by the carrier of the prior art. This indicates that said additive adheres more strongly to the surface of the carrier particles, it is released much less from the carrier of the present invention during inhalation, and it is hence less available for systemic absorption.
  • formulations comprising the carrier of the present invention also turned out to be physically stable in the device before use.
  • the carrier particles of the present invention tend to adsorb less water as demonstrated by the dynamic vapor sorption experiments, making them particularly useful for preparing dry powder formulations comprising hydrophobic and/or hydrophilic active ingredients.
  • the present invention provides pharmaceutical compositions in the form of a dry powder for inhalation comprising the carrier particles of the present invention and one or more active ingredients.
  • the active ingredient may be practically any pharmaceutically active compound which can be administered by inhalation of a dry powder.
  • beta 2 -agonists such as terbutalin, reproterol, salbutamol, salmeterol, formoterol, carmoterol, milveterol, indacaterol, olodaterol, fenoterol, clenbuterol, bambuterol, broxaterol, epinephrin, isoprenaline or hexoprenaline or salts and/or solvate forms thereof; short-acting and long-acting anticholinergics such as tiotropium, ipratropium, oxitropium, oxybutynin, aclidinium, trospium, glycopyrronium, or the compounds known with the codes GSK 573719 and GSK 1160274, in form of salts and/or solvate forms thereof; bifunctional Muscarinic Antagonist-beta2 Agonist (MABA) compounds for inhalation such as GSK
  • MABA Muscarinic Antagonist-beta2 Agon
  • Dry powder formulations of the present invention may also employ proteins, peptides, oligopeptides, polypeptides, polyamino acids nucleic acid, polynucleotides, oligo-nucleotides, and high molecular weight polysaccharides.
  • albumins preferably, human serum Insulin; albumin
  • BSA preferably, human serum Insulin; albumin
  • IgG preferably, DNAse, alphal antitrypsin; polylys
  • IgM insulin
  • GMCSF GMCSF
  • LHRH VEGF
  • hGH lysozyme
  • alpha-lactoglobulin basic fibroblast growth factor basic fibroblast growth factor
  • bFGF lysozyme
  • alpha-lactoglobulin basic fibroblast growth factor basic fibroblast growth factor
  • bFGF basic fibroblast growth factor
  • asparaginase urokinase-VEGF
  • chymotrypsin trypsin
  • streptokinase interferon
  • carbonic anhydrase ovalbumin
  • glucagon ACTH
  • oxytocin phosphorylase b
  • vasopressin levothyroxin
  • hematopoietic or thrombopoietic factors include, among others, erythropoietin, granulocyte colony stimulating factor (G-CSF), granulocyte-macrophage stimulating factor (GM-CSF) and macrophage colony stimulating factor (M-CSF), leukocyte proliferation factor preparation, thrombopoietin, platelet proliferation stimulating factor, megakaryocyte proliferation (stimulating) factor, and factor VIII; enzymes and enzyme cofactors including pancrease, L-asparaginase, hyaluronidase, chymotrypsin, trypsin, streptokinase, urokinase, pancreatin, collagena
  • enkephalins, endorphins neurotropic factor (NTF), calcitonin gene-related peptide (CGRP), thyroid hormone releasing hormone (TRH), salts and derivatives of, and neurotensin
  • NTF neurotropic factor
  • CGRP calcitonin gene-related peptide
  • TRH thyroid hormone releasing hormone
  • salts and derivatives of, and neurotensin factors acting on the gastrointestinal system including secretin and gastrin
  • factors acting on humoral electrolytes and hemal substances including factors which control hemagglutination, plasma cholesterol level or metal ion concentrations, such as calcitonin, apoprotein E and hirudin.
  • Laminin and intercellular adhesion molecule 1 represent exemplary cell adhesion factors; factors acting on the kidney and urinary tract including substances which regulate the function of the kidney, such as brain-derived natriuretic peptide (BNP), and urotensin; factors which act on the sense organs including factors which control the sensitivity of the various organs, such as substance P; chemotherapeutic agents, such as paclitaxel, mytomycin C, and doxorubicin; factors acting on the immune system including factors which control inflammation and malignant neoplasms and factors which attack infective microorganisms, such as chemotactic peptides; and naturally occurring, chemically synthesized or recombinant peptides or proteins which may act as antigens, such as cedar pollen and ragweed pollen, and these materials alone, or together, or coupled with haptens, or together with an adjuvant.
  • BNP brain-derived natriuretic peptide
  • Formulations comprising a beta 2 -agonist, an anti-cholinergic or a corticosteroid for inhalation, alone or in any combination thereof, constitute particular embodiments of the invention.
  • actives may be present in a particular salt and/or solvate form thereof, such as beta 2 -agonists, e.g. formoterol fumarate dihydrate, salbutamol sulphate, salmeterol xinafoate, milveterol hydrochloride, and indacaterol maleate; anti-cholinergics, e.g. as glycopyrronium bromide in form of (3R,2R′) enantiomer or racemic mixture (3S,2R′) and (3R,2S′), tiotropium bromide, oxytropium bromide, ipratropium bromide, oxybutynin chloride, aclidinium bromide, or trospium chloride.
  • beta 2 -agonists e.g. formoterol fumarate dihydrate, salbutamol sulphate, salmeterol xinafoate, milveterol hydrochloride, and indacaterol maleate
  • corticosteroids for inhalation instead may be present in a particular ester form and/or solvate form thereof, e.g. beclomethasone dipropionate or its monohydrate form, fluticasone propionate, fluticasone furoate, or mometasone furoate.
  • beclomethasone dipropionate or its monohydrate form e.g. beclomethasone dipropionate or its monohydrate form, fluticasone propionate, fluticasone furoate, or mometasone furoate.
  • formulations comprising the dihydrate form of formoterol fumarate and its combinations with corticosteroids for inhalation and/or anticholinergics are preferred.
  • a salt of vilanterol or indacaterol and combinations thereof with corticosteroids for inhalation and/or anticholinergics are preferred.
  • the active substance In order that the active substance is inhalable, i.e. it can pass into the deep lung such as the terminal and respiratory bronchioles and the alveolar ducts and sacs, it must be in particulate form having a mean particle diameter (measured as the mass mean diameter) of at most about 10 microns, e.g. from 1 to 10 microns, and preferably 1 to 6 microns.
  • Such microfine particles may be obtained in a manner known per se, for example by micronization, controlled precipitation from selected solvents, spray drying, supercritical fluids, or according to the processes described in WO 2004/073827, WO 2008/155570, WO 2008/114052 and WO 2010/007447, which are incorporated herein by reference in their entireties.
  • the therapeutically amount of the active substance may vary within wide limits depending on the nature of the active substance, the type and severity of the condition to be treated, and the condition of the patient in need of treatment.
  • the active substance particles are added to the carrier particles of the invention by mixing.
  • the particles may be mixed using a tumbling blender (for example a Turbula mixer) according to procedures known in the art.
  • the rotation speed of the mixer and the time of mixing shall be adjusted by the skilled person to obtain a good uniformity of distribution of the active ingredient in the formulation.
  • an excellent uniformity of distribution of the active ingredient is achieved when the active ingredient has a particle size distribution wherein no more than 10% of the particles have a volume diameter [d(v,0.1)] lower than 0.8 microns, preferably of lower than 0.9 microns, more preferably lower than 1 micron, and no more than 50% of particles have a volume diameter [d(v,0.5)] lower than 1.7 microns preferably lower than 1.9 microns, more preferably lower than 2 microns.
  • the dry powder formulation for inhalation comprising the carrier particles of the present invention may be utilized with any dry powder inhaler.
  • Dry powder inhalers can mainly be divided into: i) single-dok (unit-dose) inhalers, for the administration of single subdivided doses of the active compound; and ii) pre-metered multi-dose inhalers or reservoir inhalers pre-loaded with quantities of active principles sufficient for longer treatment cycles.
  • dry powder formulations may be presented in unit dosage form.
  • Dry powder compositions for topical delivery to the lung by inhalation may, for example, be presented in capsules and cartridges of for example gelatin, or blisters of for example laminated aluminum foil, for use in an inhaler or an insufflator.
  • the dry powder formulation for inhalation according to the present invention is particularly suitable for multi-dose dry powder inhalers comprising a reservoir from which individual therapeutic dosages can be withdrawn on demand through actuation of the device.
  • a preferred multi-dose device is the inhaler described in WO 2004/012801, which is incorporated herein by reference in its entirety.
  • multi-dose devices that may be used are for instance the DISKUSTM of GlaxoSmithKline, the TURBOHALERTM of AstraZeneca, TWISTHALERTM of Schering, and CLICKHALERTM of Innovata.
  • Alpha-lactose monohydrate commercially available was sieved to give a sample having particles with a range of diameter from 90 to 150 ⁇ m.
  • About 450 g of said alpha-lactose monohydrate mixed with 0.5% w/w of magnesium stearate was fed into the stationary conical vessel of a 1 liter laboratory model CYCLOMIXTM apparatus (Hosokawa Micron Ltd). The process was conducted using varying different parameters (rotation speed, processing time).
  • Alpha-lactose monohydrate and a mixture of alpha-lactose monohydrate and 0.5% magnesium stearate processed at 2000 r.p.m. for 15 minutes were also processed for comparative purposes.
  • the obtained particles were collected and subjected to chemico-physical technological characterization.
  • the marker band at 2850 cm ⁇ 1 in the FT-IR spectrum also confirms the presence in the samples of magnesium stearate. Representative SEM pictures are reported in FIG. 2 . From the images it can be appreciated that the treatment of carrier particles mixed with 0.5 w/w magnesium stearate at 1500 r.p.m for 5, 10, and 15 minutes does not substantially change the particle size. The same was observed for a rotation speed of 1000 r.p.m. (data not shown). On the contrary, at 2000 r.p.m. the particles of lactose begin to break, and a reduction of the particle size is observed together with the production of a significant amount of fine particles.
  • Carries according to the present invention are prepared as described in Example 1, but by mixing alpha-lactose monohydrate with 0.3% w/w magnesium stearate at 1000 r.p.m., and with 0.5% w/w magnesium stearate at 500 r.pm., at different times of mixing.
  • the obtained samples are subjected to particle size distribution, flowability determination, and water contact angle determination. The results of the water contact angles determination are reported in Table 4.
  • the carriers were prepared as described in Examples 1 and 3 at a rotation speed of 1000 r.p.m. for 15 minutes. Micronized beclomethasone dipropionate is obtained by conventional jet mill miconization. A powder formulation according to the invention is prepared with the composition reported in Table 5.
  • BDP dry powder formulation 1. Amounts Per shot of the inhaler Single dose Components Mg % microgram Beclomethasone 0.100 1.0 100 dipropionate (BDP) Alpha-lactose monohydrate 9.85 98.5 90 to 150 microns Magnesium stearate 0.05 0.5 Total weight 10
  • the final formulation is filled in the multidose dry powder inhaler described in WO 2004/012801, which is incorporated herein by reference in its entirety.
  • BDP dry powder formulation 2. Amounts Per shot of the inhaler Single dose Components Mg % microgram Beclomethasone 0.100 1.0 100 dipropionate (BDP) alpha-lactose monohydrate 9.89 98.9 90 to 50 microns Magnesium stearate 0.01 0.1 Total weight 10
  • BDP dry powder formulation 3. Amounts Per shot of the inhaler Single dose Components mg % microgram Beclomethasone 0.100 1.0 100 dipropionate (BDP) alpha-lactose monohydrate 9.87 98.7 90 to 150 microns Magnesium stearate 0.03 0.3 Total weight 10
  • the FPF which is an index of the respirable fraction, turned out to be excellent, indicating that the formulations comprising the carriers of the invention are capable of providing good aerosol performances. Said formulations also gave rise to significantly higher FPF in comparison to analogous formulations comprising a carrier prepared by mixing by mixing alpha-lactose monohydrate and magnesium stearate in a Turbula mixer at 32 r.p.m. for 120 minutes, according to U.S. Pat. No. 6,528,096.
  • the carrier was prepared as described in Example 1 at a rotation speed of 1000 r.p.m. for 10 minutes.
  • Micronized formoterol fumarate dihydrate was obtained by conventional jet mill micronization.
  • a powder formulation according to the invention was prepared with the composition reported in Table 9. The final formulation was filled in the multidose dry powder inhaler described in WO 2004/012801, which is incorporated herein by reference in its entirety.
  • Formoterol fumarate (FF) dry powder formulation 1. Amounts Per shot of the inhaler Single dose Components mg % microgram Formoterol fumarate dehydrate 0.0012 0.12 12 Alpha-lactose monohydrate 9.948 99.48 90 to 150 microns Magnesium stearate 0.05 0.5 Total weight 10
  • Said formulation also gave rise to significantly higher FPF in comparison to an analogous formulation comprising a carrier prepared by mixing by mixing alpha-lactose monohydrate and magnesium stearate in a Turbula mixer at 32 r.p.m. for 120 minutes, according to U.S. Pat. No. 6,528,096.
  • a carrier is prepared as described in Example 1 at a rotation speed of 1000 r.p.m. for 15 minutes.
  • Micronized beclomethasone dipropionate and formoterol fumarate dihydrate are obtained by conventional milling.
  • a powder formulation according to the invention is prepared with the composition reported in Table 11. The final formulation is filled in the multidose dry powder inhaler described in WO 2004/012801, which is incorporated herein by reference in its entirety.
  • Formoterol fumarate + BDP dry powder formulation Amounts Per shot of the inhaler Single dose Components mg % microgram Formoterol fumarate dehydrate 0.0006 0.06 6 Beclomethasone 0.100 1.0 100 dipropionate (BDP) Alpha-lactose monohydrate 9.77 98.44 90 to 150 microns Magnesium stearate 0.05 0.5 Total weight 10
  • a carrier is prepared as described in Example 1 at a rotation speed of 1000 r.p.m. for 15 minutes.
  • Micronized glycopyrronium bromide in the form of a racemic mixture (3S,2R′) and (3R,2S′) is obtained as described in WO 2010/007447, which is incorporated herein by reference in its entirety.
  • a powder formulation according to the invention is prepared with the composition reported in Table 12. The final formulation is filled in the multidose dry powder inhaler described in WO 2004/012801, which is incorporated herein by reference in its entirety.
  • the favorable properties of the carrier of the invention are illustrated by following experiment, where the release of Mg fine particles from a formulation thereof was investigated.
  • Samples of carriers according to the invention as described in Example 1, prepared by mixing alpha-lactose monohydrate with 0.1% w/w, 0.3% w/w, or 0.5% w/w magnesium stearate in a CYCLOMIXTM apparatus at 1000 r.p.m. for 10 minutes were filled in the multidose dry powder inhaler described in WO 2004/012801, which is incorporated herein by reference in its entirety.
  • Micronized beclomethasone dipropionate was added as reported in Example 4.
  • the respirable fraction of magnesium stearate was evaluated using a Twin Stage Impinger apparatus (TSI, Copley Instruments Ltd, UK) according to the procedure described in the FU IX, 4 th Supplement, 1996 and applying a air flow of 601/minute.
  • the limit value of the aerodynamic diameter (d ae ) for deposition in the lower separating chamber is 6.4 microns. Particles with larger d ae are deposited in Stage 1, while particles with smaller d ae in Stage 2.
  • Ten doses of 15-18 mg were delivered for each experiment.
  • the TSI apparatus was dismantled and the amounts of particles deposited in two separated chambers were harvested with a mixture of water:acetonitrile:HCl (2N) 40:40:20 v/v/v and brought up to a volume of 50 ml.
  • the samples were calcinated in a microwave oven and the amount of Mg was determined by flame atomic absorption spectroscopy using a Perkin-Elmer instrument Analyst 800, according to standard procedures known in the art.
  • the limit of detection (LOD) turned out to be 0.062 mg/ml.
  • the respirable fraction (FPF) of magnesium state was calculated by the ratio between the respirable dose and the delivered (emitted) dose.
  • the delivered dose is calculated from the cumulative deposition in the apparatus, while the respirable dose is calculated from the deposition on Stages 2 corresponding to particles with a d ae ⁇ 6.4 micron.
  • the results are reported in Table 13 (mean ⁇ .S.D.).
  • the percentage of respirable magnesium stearate particles delivered by the carrier of the present invention is significant lower that the percentage delivered by a comparative carrier. This indicates that said additive is released much less from the carrier of the present invention during inhalation, as it adheres more strongly to the surface of the carrier particles, and, hence, it is less available for systemic absorption.
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